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American Association State Highway

Designation: A 153/A 153M 023 and Transportation Officials Standard
AASHTO No. M232

Standard Specification for

Zinc Coating (Hot-Dip) on Iron and Steel Hardware1
This standard is issued under the fixed designation A 153/A 153M; the number immediately following the designation indicates the year
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

This standard has been approved for use by agencies of the Department of Defense.

1. Scope
1.1 This specification covers zinc coatings applied by the hot-dip process on iron and steel hardware.
1.2 This specification is intended to be applicable to hardware items that are centrifuged or otherwise handled to remove excess
galvanizing bath metal (free zinc). Coating thickness grade requirements reflect this.
1.3 This specification is applicable to orders in either inch-pound units (as A 153) or in SI units (as A 153M). Inch-pound units
and SI units are not necessarily exact equivalents. Within the text of this specification and where appropriate, SI units are shown
in parentheses. brackets. Each system shall be used independently of the other without combining values in any way. In the case
of orders in SI units, all testing and inspection shall be done using the metric equivalent of the test or inspection method as
appropriate. In the case of orders in SI units, such shall be stated to the galvanizer when the order is placed.
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory
limitations prior to use.
2. Referenced Documents
2.1 ASTM Standards:

1
This specification is under the jurisdiction of ASTM Committee A05 on Metallic-Coated Iron and Steel Products and is the direct responsibility of Subcommittee A05.13
on Structural Shapes and Hardware Specifications.
Current edition approved December April 10, 20023. Published February May 2003. Originally approved in 1933. Last previous edition approved in 20012 as
A 153/A 153M 01a2.

Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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 A 153/A 153M 023
A 90/A 90M Test Method for Weight of Coating on Zinc-Coated (Galvanized) Iron or Steel Articles2
A 143 Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for
Detecting Embrittlement2
A 385 Practice for Providing High-Quality Zinc Coatings (Hot-Dip)2
A 780 Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings2
A 902 Terminology Relating to Metallic Coated Steel Products2
B 6 Specification for Zinc (Slab Zinc)3
B 487 Test Method for Measurement of Metal and Oxide Coating Thicknesses by Microscopical Examination of a Cross
Section4
B 602 Test Method for Attribute Sampling of Metallic and Inorganic Coatings4
E 376 Practice for Measuring Coating Thickness by Magnetic-Field or Eddy-Current (Electromagnetic) Test Methods5
F 1470 Guide for Fastener Sampling for Specified Mechanical Properties and Performance Inspection6
F 1789 Terminology for F16 Mechanical Fasteners6
3. Terminology
3.1 Definitions:
3.1.1 The following terms and definitions are specific to this specification. Terminology A 902 contains other terms and
definitions relating to metallic-coated steel products. Terminology F 1789 contains other terms and definitions relating to
mechanical fasteners.
3.2 Definitions of Terms Specific to This Standard:
3.2.1 average coating thickness, nthe average of the specimen coating thickness values for the samples in an inspection lot.
3.2.2 bare spots, nuncoated areas on the surface of the steel part that contain no measurable zinc coating.
3.2.3 dross inclusions, nthe iron/zinc intermetallics present in a galvanized coating in a form other than the layer growth of
the coating.
3.2.4 individual measurement, nthe reading from a magnetic thickness gauge of a single coating spot thickness, or the
microscopic reading of a coating thickness as seen in an optical microscope at one spot.
3.2.5 inspection lot, nthe quantity of identical parts cleaned, fluxed and galvanized together at one time in an appropriate
container that is being submitted for acceptance as a group.
3.2.6 malleable casting, na steel article that has been subjected to a prolonged anneal to decarburize or graphitize the part
to remove as much of the carbon as possible or to convert the carbon to graphite, which permits plastic deformation in compression
without rupture.
3.2.7 sample, na collection of individual units of product from a single inspection lot selected in accordance with Section 6
and intended to represent that inspection lot for acceptance.
3.2.8 specimen, nan individual test article upon which thickness measurements or weight determinations are performed.
3.2.9 specimen coating thickness, nthe average thickness from no less than five test measurements on a specimen, when each
measurement location is selected to provide the widest dispersion (in all applicable directions) of locations within the specimen
volume.
3.2.10 threaded areas, nthe sections of a steel part that have threads formed before hot-dip galvanizing.
4. Materials and Manufacture
4.1 Steel or IronFerrous articles to be hot-dip zinc coated shall conform to specifications designated by the purchaser.
4.2 ZincThe zinc used for the coating shall conform to Specification B 6 and shall be at least equal to the grade designated
as Prime Western.
4.2.1 If a zinc alloy is used as the primary feed for the galvanizing bath, then the base material used to make that alloy shall
conform to Specification B 6.
4.2.2 The molten metal in the working volume of the galvanizing bath shall contain not less than an average value of 98.0 %
zinc by weight [mass].
NOTE 1The galvanizer may choose to add trace amounts of certain elements (for example, aluminum, nickel, bismuth, or tin) to the zinc bath to help
in the processing of certain reactive steels or to enhance the cosmetic appearance of the finished product. The elements can be added to the galvanizing
bath as a master feed alloy, or they can be added to the bath by the galvanizer as individual feeds.
4.3 Minimum Coating Weight [Mass] or Minimum Coating Thickness GradeThe thickness grades of minimum coating weight
[mass] or the minimum coating thickness shall conform to the requirements prescribed in Table 1 for the material category and
thickness of material in which the article belongs.

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Annual Book of ASTM Standards, Vol 01.06.
3
Annual Book of ASTM Standards, Vol 02.04.
4
Annual Book of ASTM Standards, Vol 02.05.
5
Annual Book of ASTM Standards, Vol 03.03.
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Annual Book of ASTM Standards, Vol 01.08.

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 A 153/A 153M 023
TABLE 1 Thickness or Weight [Mass] of Zinc Coating for Various Classes of Material

NOTE 1 Length of the piece, stated in Classes B-1, B-2, and B-3, refers to the overall dimension and not to its developed length.
NOTE 2Based upon mathematical calculations, 1 oz /ft2 of zinc surface corresponds to an average coating thickness of 1.7 mil. (Based upon
mathematical calculations, 1 g/m2 of zinc surface corresponds to an average coating thickness of 0.141 m; seven times the coating thickness in
micrometres is approximately equal to the coating in g/m2.) References to coating thickness or coating thickness grade throughout this standard are
interchangeable with weight in Table 1, in accordance with the above calculation.
MinimumWeight [Mass] of Zinc Coating, Coating Thickness, mils
oz/ft2([g/m2)] of SurfaceA, Minimum [microns], Minimum

Class of Material Average of Speci- Any Individual Speci- Average of Any

mens TestedB men Specimens Individual
Specimens Individual Tested Specimen
Tested Specimen
Class ACastingsMalleable Iron, Steel 2.00 (610) 1.80 (550) 3.4 [86] 3.1 [79]
Class ACastingsMalleable Iron, Steel 2.00 [610] 1.80 [550] 3.4 [86] 3.1 [79]
Class BRolled, pressed, and forged articles (except those
which would be included
under Classes C and D):
Class BRolled, pressed, and forged articles (except those
which would be included
(except those which would be included under Classes C and D):
B-1316 in. (4.76 mm) and over in thickness and over 15 in. 2.00 (610) 1.80 (550) 3.4 [86] 3.1 [79]
(381 mm) in length

B-1316 in. [4.76 mm] and over in thickness 2.00 [610] 1.80 [550] 3.4 [86] 3.1 [79]
and over 15 in. [381 mm] in length
B-2under 316 in. (4.76 mm) in thickness and over 15 in. 1.50 (458) 1.25 (381) 2.6 [66] 2.1 [53]
(381 mm) in length

B-2under 316 in. [4.76 mm] in thickness and 1.50 [458] 1.25 [381] 2.6 [66] 2.1 [53]
over 15 in. [381 mm] in length
B-3any thickness and 15 in. (381 mm) and under in length 1.30 (397) 1.10 (336) 2.2 [56] 1.9 [48]
B-3any thickness and 15 in. (381 mm) and under in length 1.30 [397] 1.10 [336] 2.2 [56] 1.9 [48]
Class CFasteners over 38 in. (9.52 mm) in diameter and simi- 1.25 (381) 1.00 (305) 2.1 [53] 1.7 [43]
lar articles. Washers 316 in.
and 14 in. (4.76 and 6.35 mm) in thickness
Class CFasteners over 38 in. [9.52 mm] in diameter 1.25 [381] 1.00 [305] 2.1 [53] 1.7 [43]
and similar articles. Washers 316 in. and 14 in. [4.76 and 6.35
mm] in thickness
Class DFasteners 38 in. (9.52 mm) and under in diameter, 1.00 (305) 0.85 (259)] 1.7 [43] 1.4 [36]
rivets, nails and similar
articles. Washers under 316 in. (4.76 mm) in thickness
Class DFasteners 38 in. [9.52 mm] and under in diameter, 1.00 [305] 0.85 [259] 1.7 [43] 1.4 [36]
rivets, nails and similar articles. Washers under 316 in. [4.76
mm] in thickness
A
In the case of long pieces, such as anchor rods and similar articles over 5 ft (1.52 m) in length, the weight of coating shall be determined at each end and the middle
of the article. In no case shall individual measurements be below the minimum shown in the Any Individual Specimen column.
B
The number of specimens to be tested per order shall be as specified in Section 8.

4.4 Threaded ArticlesThe zinc coating on threads shall not be subjected to a cutting, rolling, or finishing-tool operation, unless
specifically authorized by the purchaser. In order to meet overtapping allowances, tapping the threads of nuts or tapped holes after
galvanizing is not prohibited.
4.5 Touch-up and RepairBare spots that are found on parts after galvanizing shall be renovated by use of the methods found
in Practice A 780 if the following criteria are met. The bare spots shall have an area totalling not more than 1 % of the surface
area to be coated excluding threaded areas of the piece and the bare spots shall not include any threaded areas of the piece. The
thickness of the repair shall be equal to the surrounding galvanized coating except for repairs made by paints containing zinc dust
in which case the thickness of the repair shall be 50 % greater than the thickness of the galvanized coating required for the class
of material, but shall not be greater than 4.0 mils ( [100 m)]. Repair thickness measurements shall be made in accordance with
Practice A 780. The galvanizer shall make repairs unless directed by the purchaser to deliver items unrepaired for subsequent
renovation by the purchaser.
5. Workmanship, Finish, and Appearance
5.1 The zinc-coated articles shall be free from uncoated areas, blisters, flux deposits, dross inclusions, and other types of
projections that would interfere with the intended use of the articles, or other defects not consistent with good galvanizing practice.
5.2 The zinc coating shall be smooth and reasonably uniform in thickness.
NOTE 12Smoothness of surface is a relative term. Minor roughness that does not interfere with the intended use of the part, or roughness that is
related to the as-received (ungalvanized) surface condition of the part, shall not be grounds for rejection.
NOTE 23Since this specification is applicable to items that are centrifuged or otherwise handled to remove excess bath metal (see 1.2), irregular
coating distribution is not normally encountered. Drainage problems, which manifest themselves as local excess coating thickness that would interfere
with function or as edge tears or spikes that present a safety hazard because of their sharpness, are grounds for rejection under the terms of 6 5.1.

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 A 153/A 153M 023
5.3 Embrittlement is a potential condition of steel that is cold-worked, depending on such factors as the steel type (strength
level, aging characteristics), thickness, degree of cold work, and galvanizing process. The galvanizer, the designer and the
fabricator shall take precautions against embrittlement. The precautions to fabricate properly and prepare the material for
galvanizing to prevent embrittlement are described in Practice A 143.
NOTE 34Low service temperatures increase the risk of brittle failure of all plain carbon steels including those which have been galvanized. This
temperature embrittling effect varies with type of steel. The expected service temperature should thus be taken into account when selecting steels for
galvanizing.
5.4 Malleable castings shall be of such composition as will preclude the possibility that they become embrittled by the
galvanizing process, or they shall be either cooled from the anneal, or subsequently heat-treated so as to immunize them against
embrittlement.
5.5 The zinc coating shall adhere tenaciously to the surface of the basis metal (see Section 9). base metal.
5.6 If the galvanized material covered by this specification is bent or otherwise fabricated to the degree that causes the zinc
coatings to stretch or compress beyond the limit of elasticity, any cracking or flaking of the coating resulting from the bending or
fabricating shall not be cause for rejection.
6. Sampling
6.1 Test specimens shall be selected at random from each inspection lot.
6.2 The method of selection and sample size shall be agreed upon between the galvanizer and the purchaser. Otherwise, the
sample size selected from each lot shall be as follows:
Number of Pieces in Lot Sample Size
3 or less all
4 to 500 3
501 to 1200 5
1201 to 3200 8
3201 to 10 000 13
10 001 and over 20

6.3 A specimen that fails to conform to a requirement of this specification shall not be used to determine the conformance to
other requirements.
6.4 The method of sampling for fasteners that are required to meet the standards of the Fastener Quality Act is described in
Guide F 1470. Sample quantities and definitions of terminology are included in the referenced specification.
7. Test Methods
7.1 Tests shall be made to ensure that the zinc coating is being furnished in accordance with this specification and as specified
for the following:
7.1.1 Thickness of coating in 4.3.
7.1.2 Finish and appearance in 5.1 and 5.2.
7.1.3 Embrittlement in 5.3 and 5.4.
7.1.4 Adherence in 5.5.
7.2 Thickness of Coating:
7.2.1 The average weight of the zinc coating shall be determined by weighing specimens after pickling and drying and again
after galvanizing unless the method described in 7.2.2 or 7.2.3 is used.
NOTE 45This method does not take into account the weight of iron reacted from the article that is incorporated into the coating. It will thus
underestimate coating weight by up to approximately 10 %. Base metal reactivity will affect the extent of underestimation.
7.2.2 In the case of materials inspected after galvanizing, the weight of coating shall be determined by stripping one or more
specimens in accordance with Test Method A 90/A 90M, or the average thickness of coating shall be determined with the use of
a magnetic thickness gage in conformity with Practice E 376, unless the method described in 7.2.1 or 7.2.3 is used.
7.2.2.1 In the case of fasteners such as bolts, nuts, and screws, the determination of the thickness of coating shall be made on
a portion of the article that does not include any threads.
7.2.3 The thickness of coating shall be determined by cross section and optical measurement, unless the method described in
7.2.1 or 7.2.2 is used. The thickness thus determined is a point value. No less than five such measurements shall be made at
locations on the test article, which are as widely dispersed as practical, so as to be representative of the whole surface of the test
article. The average of no less than five such measurements is the specimen coating thickness.
7.3 EmbrittlementHardware that is susceptible to embrittlement shall be tested in accordance with Practice A 143. The tests
shall be performed through agreement between the galvanizer and the purchaser.
7.4 AdherenceDetermine adherence of the zinc coating to the surface of the base metal by cutting or prying with the point
of a stout knife, applied with considerable pressure in a manner tending to remove a portion of the coating. The adherence shall
be considered inadequate if the coating flakes off in the form of a layer of skin so as to expose the base metal in advance of the
knife point. Do not use testing carried out at edges or corners (points of lowest coating adherence) to determine adherence of
coating. Likewise, do not use removal of small particles of the coating by paring or whittling to determine failure.

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 A 153/A 153M 023
8. Inspection
8.1 The inspector representing the purchaser shall have access at all times while work on the contract of the purchaser is being
performed, to those areas of the manufacturers work which concern the application of the zinc coating to the material ordered.
The manufacturer shall afford the inspector all reasonable facilities to satisfy him that the zinc coating is being furnished in
accordance with this specification. All inspection and tests shall be made at the place of manufacture prior to shipments, unless
otherwise specified, and shall be so conducted as not to interfere unnecessarily with the operation of the works.
9. Rejection and Retest
9.1 For all galvanized articles except those fasteners that must meet the requirements of the Fastener Quality Act, the following
sections are used to determine rejection and retesting.
9.2 When partial inspection of materials to determine conformity with visual requirements of Section 5 warrants rejection of
a lot, the galvanizer is not prohibited from sorting the lot and submitting it once again for inspection.
9.3 The number of specimens in a sample of a lot permitted to fail to conformance tests shall be agreed upon between the
galvanizer and the purchaser.
9.4 If a set of test specimens fails to conform to the requirements of this specification, two additional sets shall be tested, both
of which shall conform to the requirements in every respect, or the lot of material represented by the specimens shall be rejected.
9.5 Materials that have been rejected for reasons other than embrittlement are not prohibited from being stripped, regalvanized,
and resubmitted for test and inspection. They shall then conform to the requirements of this specification.
10. Packaging
10.1 The supplier shall employ such methods of packaging zinc-coated articles as shall be required to ensure their receipt by
the purchaser in satisfactory condition, with the use to be made of the article being taken into consideration.
11. Certification
11.1 When specified in the purchase order or contract, the purchaser shall be furnished certification that samples representing
each inspection lot have been either tested or inspected as directed by this specification and the requirements have been met. When
specified in the purchase order or contract, a report of the test results shall be furnished.
12. Keywords
12.1 coatings, zinc; galvanized coatings; steel hardware, zinc coated; steel products, metallic coated; zinc coatings, steel
products

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